Head-mounted-display system including three-dimensional knitted layer

ABSTRACT

A head-mounted-display assembly may include a knitted layer formed of a plurality of fibers and extending in three dimensions. The knitted layer may include (1) a first region having a first degree of at least one physical property, (2) a second region having a second degree of the at least one physical property, and (3) a transition region extending between the first region and the second region. The transition region of the knitted layer may progressively change in degree of the at least one physical property proceeding from the first region toward the second region. Various other apparatuses, systems, and methods are also disclosed.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/890,582, filed Feb. 7, 2018, the disclosure of which is incorporatedherein, in its entirety, by this reference.

BACKGROUND

Virtual reality and augmented reality headsets are widely gaining inpopularity for use in a growing number of activities. Such headsets mayintegrate visual information into a user's field of view to enhancetheir surroundings or allow them to step into realisticthree-dimensional environments. While virtual reality and augmentedreality headsets are often utilized for gaming and other entertainmentpurposes, they are also commonly employed for purposes outside ofrecreation—for example, governments may use them for military trainingsimulations, doctors may use them to practice surgery, and engineers mayuse them as visualization aids. Virtual and augmented reality systemsare also increasingly recognized for their utility in facilitatinginter-personal interactions between individuals in a variety ofcontexts.

However, substantial electronics and optical systems are often requiredto deliver immersive, high-definition images to users. Such componentsmay add significant weight to virtual reality and augmented realityheadsets, presenting difficulties in securely and comfortably mountingsuch headsets to users' heads. Strap systems, which are commonly used tofasten headsets to users' heads, may be uncomfortable to users and mayprovide an inadequate degree of adjustability. Additionally, headsethousings may also add to the weight of the headsets and may allow foronly limited adjustment to accommodate users' unique facial features.Improving the comfort level and adjustability of virtual reality andaugmented reality headsets may require the addition of various partsthat increase the complexity, cost, and weight of the headsets whilediminishing their aesthetic appearance.

SUMMARY

As will be described in greater detail below, the instant disclosuredescribes various head-mounted-display apparatuses, assemblies, andsystems including three-dimensional knitted layers and methods formanufacturing the same. In one example, a head-mounted-display assemblymay include a knitted layer formed of a plurality of fibers andextending in three dimensions. The knitted layer may include (1) a firstregion having a first degree of at least one physical property, (2) asecond region having a second degree of the at least one physicalproperty, and (3) a transition region extending between the first regionand the second region. The transition region of the knitted layer mayprogressively change in degree of the at least one physical propertyproceeding from the first region toward the second region.

According to some embodiments, the at least one physical property mayinclude at least one of rigidity, elasticity, flexibility,deformability, or bondability to at least one specified material. Insome examples, the plurality of fibers may include a plurality of yarns,each of the plurality of yarns including multiple fibers. In at leastone example, the knitted layer may include at least a portion of adisplay housing for mounting at least one head-mounted-displaycomponent. In various examples, the knitted layer may include at least aportion of at least one of a front-facing portion or a side portion ofthe display housing. The side portion of the display housing may extendfrom the front-facing portion toward a viewing opening dimensioned tosurround at least a portion of a user's face. In this example, the firstregion of the knitted layer may include a mounting region for mountingthe at least one head-mounted-display component. The first region of theknitted layer may have a higher degree of rigidity than the secondregion of the knitted layer. The knitted layer may include at least aportion of a strap subsystem dimensioned to extend around at least aportion of a user's head.

According to at least one embodiment, the plurality of fibers mayinclude a first type of fiber and a second type of fiber that includes adifferent material than the first type of fiber. In this example, atleast one of the first type of fiber and the second type of fiber mayinclude at least one of a thermoplastic material, a thermosettingmaterial, or a curable material. Additionally or alternatively, thefirst region of the knitted layer may include a first proportion of thefirst type of fiber to the second type of fiber, and the second regionof the knitted layer may include a second proportion of the first typeof fiber to the second type of fiber. In this example, the secondproportion may differ from the first proportion. In some embodiments,the first region may have a first average layer thickness and the secondregion may have a second average layer thickness that differs from thefirst average layer thickness. In various embodiments, at least aportion of an electrical circuit may be disposed in the knitted layer.

In some embodiments, a head-mounted-display system may include a knittedlayer formed of a plurality of fibers and extending in three dimensions.The knitted layer may include (1) a first region having a first degreeof at least one physical property, and (2) a second region having asecond degree of the at least one physical property. At least oneelectronic component may be mounted to the first region of the knittedlayer. According to some examples, the at least one electronic componentmay be mounted to the first region of the knitted layer by at least oneof bonding or mechanical fastening. In various examples, the firstregion of the knitted layer may have a higher degree of rigidity thanthe second region of the knitted layer.

A corresponding method may include (1) knitting together a plurality offibers to form a knitted layer of a head-mounted-display assembly, theknitted layer extending in three dimensions. The knitted layer mayinclude at least two regions which, when processed, cause (1) a firstregion to have a first degree of at least one physical property and (2)a second region to have a second degree of the at least one physicalproperty. A transition region may extend from the first region to thesecond region and may progressively change in degree of the at least onephysical property proceeding from the first region toward the secondregion.

According to some embodiments, during processing, at least a portion ofthe knitted layer may be exposed to at least one of elevated heat,elevated pressure, light, radiation, or at least one chemical agentsufficient to modify the at least one physical property of at least theportion of the knitted layer. Additionally or alternatively, duringprocessing, at least a portion of the knitted layer may be at least oneof softened, melted, cured, or molded. In at least one example, thefirst region of the processed knitted layer may be configured to have atleast one head-mounted-display component mounted thereto. In someexamples, the at least one head-mounted-display component may be mountedto the first region of the processed knitted layer by at least one ofbonding or mechanically fastening the at least one head-mounted-displaycomponent to the first region of the processed knitted layer. In someembodiments, the first region of the knitted layer may include a firstproportion of a first type of fiber to a second type of fiber.Additionally or alternatively, the second region of the knitted layermay include a second proportion of the first type of fiber to the secondtype of fiber. In this example, the second proportion may differ fromthe first proportion.

Features from any of the above-mentioned embodiments may be used incombination with one another in accordance with the general principlesdescribed herein. These and other embodiments, features, and advantageswill be more fully understood upon reading the following detaileddescription in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate a number of exemplary embodimentsand are a part of the specification. Together with the followingdescription, these drawings demonstrate and explain various principlesof the instant disclosure.

FIG. 1 is a perspective view of an exemplary head-mounted-display systemin accordance with some embodiments.

FIG. 2 is a schematic illustration of a portion of an exemplary knittedlayer in accordance with some embodiments.

FIG. 3 is a schematic illustration of a portion of an exemplary knittedlayer in accordance with some embodiments.

FIG. 4 is a perspective view of an exemplary display housing inaccordance with some embodiments.

FIG. 5 is a bottom view of an exemplary display housing in accordancewith some embodiments.

FIG. 6 is a partial cross-sectional side view of an exemplaryhead-mounted-display device in accordance with some embodiments.

FIG. 7 is a cross-sectional side view of a portion of an exemplarydisplay housing in accordance with some embodiments.

FIG. 8 is a cross-sectional side view of a head-mounted-displaycomponent mounted bonded to a portion of a knitted layer of an exemplarydisplay housing in accordance with some embodiments.

FIG. 9 is a cross-sectional side view of a portion of a knitted layer ofan exemplary display housing in accordance with some embodiments.

FIG. 10 is a cross-sectional side view of a head-mounted-displaycomponent mounted to a portion of a knitted layer of an exemplarydisplay housing in accordance with some embodiments.

FIG. 11 is a perspective view of an exemplary strap subsystem inaccordance with some embodiments.

FIG. 12 is a perspective view of a portion of an exemplary strapsubsystem coupled to a portion of an exemplary display housing inaccordance with some embodiments.

FIG. 13 is a side view of a portion of a knitted layer of an exemplaryhead-mounted-display system that includes wiring disposed within theknitted layer in accordance with some embodiments.

FIG. 14 is a cross-sectional view of a portion of an exemplaryhead-mounted-display system that includes wiring disposed within theknitted layer in accordance with some embodiments.

FIG. 15 is a flow diagram of an exemplary method for forming a knittedlayer of a head-mounted-display system in accordance with someembodiments.

Throughout the drawings, identical reference characters and descriptionsindicate similar, but not necessarily identical, elements. While theexemplary embodiments described herein are susceptible to variousmodifications and alternative forms, specific embodiments have beenshown by way of example in the drawings and will be described in detailherein. However, the exemplary embodiments described herein are notintended to be limited to the particular forms disclosed. Rather, theinstant disclosure covers all modifications, equivalents, andalternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present disclosure is generally directed to head-mounted-displaysystems including three-dimensional knitted layers. As will be explainedin greater detail below, embodiments of the instant disclosure mayinclude a knitted layer formed of a plurality of fibers and extending inthree dimensions. Such a knitted layer may be included in at least aportion of a display housing and/or strap subsystem of ahead-mounted-display system. The knitted layer may include differentregions having different degrees of one or more physical properties(e.g., rigidity, elasticity, flexibility, or deformability, bondabilityto at least one specified material, etc.). For example, the knittedlayer may include a first region having a first degree of at least onephysical property and a second region having a second degree of the atleast one physical property. The knitted layer may also include atransition region extending between the first region and the secondregion. The transition region may progressively change in degree of theat least one physical property proceeding from the first region towardthe second region.

Such knitted layers may allow for head-mounted-display systems to beconstructed with greater customizability and freedom of design.Different portions of a knitted layer may have distinct characteristics,enabling parts of a head-mounted-display system that are conventionallyassembled from multiple pieces to be formed from a single seamlesspiece. The knitted layers may allow for an increased range of physicalproperties to be included in various regions of the head-mounted-displaysystems. For example, a display housing and/or a strap subsystem may beformed from a continuous knitted layer having various rigid sections,semi-rigid sections, flexible sections, and/or elastic sections,eliminating the need for assembling separate pieces having theserespective characteristics. Such continuous knitted layers may havestructurally supportive regions as well as adaptive regions that conformto a user's unique head and facial features, increasing a user's comfortlevel while wearing the head-mounted-display system. The knitted layersmay also reduce the weight of head-mounted-display systems along withreductions in raw material requirements, assembly time, and productioncosts. Additionally, the aesthetic appeal of head-mounted-displaysystems incorporating seamless knitted layers may be improved throughthe elimination of bulky components and/or visible junctions betweenvarious components of the systems.

The following will provide, with reference to FIGS. 1-14, detaileddescriptions of exemplary head-mounted-display systems, devices, andassociated components that include three-dimensional knitted layers.Additionally, the discussion corresponding to FIG. 15 will provideexamples of methods for producing head-mounted-display systems thatinclude three-dimensional knitted layers.

FIG. 1 is a perspective view of a head-mounted-display system 100 inaccordance with some embodiments. In some embodiments,head-mounted-display system 100 may include a head-mounted-displaydevice 102, a strap subsystem 114, and audio subsystems 116.Head-mounted-display device 102 may include any type or form of displaydevice or system that is worn on or about a user's head and displaysvisual content to the user. Head-mounted-display device 102 may displaycontent in any suitable manner, including via a screen (e.g., a liquidcrystal display (LCD) or a light-emitting diode (LED) screen), aprojector, a cathode ray tube, an optical mixer, etc.Head-mounted-display device 102 may display content in one or more ofvarious media formats. For example, head-mounted-display device 102 maydisplay videos, photos, and/or computer-generated imagery (CGI).Head-mounted-display device 102 may include a display housing 110surrounding components of head-mounted-display device 102, includinglenses 104 and various structural, mechanical, and electroniccomponents, including display components as described herein. Displayhousing 110 may define an opening surrounding a viewing region 106configured to surround a portion of a user's face and field of view.Additionally, display housing 110 may include a front-facing portion 112disposed away from viewing region 106 and side surfaces extending fromfront-facing portion 112 and surrounding the internal components ofhead-mounted-display device 102.

Head-mounted-display devices may provide diverse and distinctive userexperiences. Some head-mounted-display devices may providevirtual-reality experiences (i.e., they may display computer-generatedor pre-recorded content), while other head-mounted displays may providereal-world experiences (i.e., they may display live imagery from thephysical world). Head-mounted displays may also provide any mixture oflive and virtual content. For example, virtual content may be projectedonto the physical world (e.g., via optical or video see-through), whichmay result in augmented reality or mixed reality experiences.Head-mounted-display devices may be configured to be mounted to a user'shead in a number of ways. Some head-mounted-display devices may beincorporated into glasses or visors. Other head-mounted-display devicesmay be incorporated into helmets, hats, or other headwear.

Embodiments of the invention may include or be implemented inconjunction with an artificial reality system. Artificial reality is aform of reality that has been adjusted in some manner beforepresentation to a user, which may include, e.g., a virtual reality (VR),an augmented reality (AR), a mixed reality (MR), a hybrid reality, orsome combination and/or derivatives thereof. Artificial reality contentmay include completely generated content or generated content combinedwith captured (e.g., real-world) content. The artificial reality contentmay include video, audio, haptic feedback, or some combination thereof,and any of which may be presented in a single channel or in multiplechannels (such as stereo video that produces a three-dimensional effectto the viewer). Additionally, in some embodiments, artificial realitymay also be associated with applications, products, accessories,services, or some combination thereof, that are used to, e.g., createcontent in an artificial reality and/or are otherwise used in (e.g.,perform activities in) an artificial reality. The artificial realitysystem that provides the artificial reality content may be implementedon various platforms, including a head-mounted display (HMD) connectedto a host computer system, a standalone HMD, a mobile device orcomputing system, or any other hardware platform capable of providingartificial reality content to one or more viewers.

In some embodiments, audio subsystems 116 may be integrated withhead-mounted-display device 102 and may provide audio signals to theuser's ears via audio headsets in conjunction with or separate fromdisplayed content. Head-mounted-display system 100 may, for example,have two audio subsystems 116 located on the left and right sides ofhead-mounted-display system 100 to provide audio signals to the user'sleft and right ears, as shown in FIG. 1.

Strap subsystem 114 may be used for adjustably mountinghead-mounted-display device 102 on the user's head. As shown in FIG. 1,strap subsystem 114 may include lower straps and/or an upper strap thatare coupled to head-mounted-display device 102 to adjustably conform tothe top and/or sides of the user's head when the user is wearinghead-mounted-display system 100, as will be described in greater detailbelow. In some embodiments, strap assembly 114 may include a back piececoupled with the upper strap and lower straps to rest against the backof the user's head (e.g., around the user's occipital lobe). In at leastone embodiment, the back piece may include an opening that isdimensioned and positioned to securely fit around a back portion (e.g.,a portion of the user's occipital lobe) of the user's head.

In some embodiments, facial interface 108 may be configured tocomfortably rest against a region of the user's face, including a regionsurrounding the user's eyes, when head-mounted-display system 100 isworn by the user. In these embodiments, facial interface 108 may includea cushion member and/or a cushioned region that is configured to restagainst portions of the user's face (e.g., at least a portion of theuser's nasal, cheek, temple, and/or forehead facial regions). Facialinterface 108 may surround viewing region 106, which includes the user'sfield of vision, allowing the user to look through lenses 104 ofhead-mounted-display device 102 without interference from outside lightwhile the user is wearing head-mounted-display system 100.

In some embodiments, head-mounted-display device 102 may also include alight-blocking layer 118 surrounding lenses 104. Light-blocking layer118 may, for example, extend between lenses 104 and surrounding portionsof display housing 110. Light-blocking layer 118 may include, forexample, a light-absorbing material (e.g., a dark polymeric and/orfabric material) that masks internal components of head-mounted-displaydevice 102 and that prevents any outside light incidentally enteringviewing region 106 (e.g., through a gap between the user's face andfacial interface 108) from being reflected within viewing region 106.

FIGS. 2 and 3 respectively illustrate exemplary knitting configurationsthat may be utilized in knitted layers for head-mounted-display systems.One or more knitting techniques may be utilized to form a knitted layerfor the head-mounted-display systems described herein. FIG. 2illustrates an exemplary portion of a knitted layer 120 formed by a weftknitting process and FIG. 3 illustrates an exemplary portion of aknitted layer 220 formed by a warp knitting process in accordance withvarious embodiments. Warp knitting and/or weft knitting may facilitateformation of knitted layers having a broad range of highly customizablecharacteristics.

As shown in FIG. 2, knitted layer 120 formed by a weft knittingtechnique may include at least one fiber follows a meandering path,forming a series of interlocking loops. The at least one fiber mayinclude, for example, at least one individual fiber (e.g., a filament)and/or at least one yarn and/or thread that includes multiple fibers.Loops formed by one course of a fiber or combination of fibers (e.g., ayarn, a thread, etc.) may be interlocked with loops formed by adjacentcourses of one or more fibers or combinations of fibers. For example, asillustrated in FIG. 2, loops of a first course 125A of a first fibersection 122A may be respectively interlocked with loops of a secondcourse 125B of a second fiber section 122B and loops of a third course125C of a third fiber section 122C. First fiber section 122A, secondfiber section 122B, and third fiber section 122C may be portions of asingle fiber or portions of two or more separate fibers. A portion ofknitted layer 120 formed by weft knitting may include wales (i.e.,sequences of stitches that are suspended from adjacent stitches) thatextend in a direction that is substantially perpendicular to thedirection of the fiber courses.

Knitted layer 220 formed by a warp knitting technique, as illustrated inFIG. 3, may include at least one fiber and/or thread that follows azigzagging path, forming a series of interlocking loops. Loops formed byone course of a fiber or combination of fibers (e.g., a yarn, a thread,etc.) may be interlocked with loops formed by adjacent courses of a oneor more fibers or combinations of fibers. For example, as shown in FIG.3, loops of a first course 225A of a first fiber section 222A may berespectively interlocked with loops of a second course 225B of a secondfiber section 222B and loops of a third course 225C of a third fibersection 222C. First fiber section 222A, second fiber section 222B, andthird fiber section 222C may be portions of a single fiber or portionsof two or more separate fibers. In contrast to knitted layer 120 formedby weft knitting, a portion of knitted layer 220 formed by warp knittingmay include wales that extend in a direction that is substantiallyparallel to the direction of the fiber courses.

One or more knitting techniques, such as weft knitting, warp knitting,and/or any other suitable technique, may be utilized to a form knittedlayers as described herein. Other techniques for knitting, weaving,and/or otherwise manipulating fibers, including, for example, yarnsand/or threads formed of multiple fibers, may additionally oralternatively be utilized in the formation of knitted layers, withoutlimitation. Such techniques may include, for example, interweaving,intertwining, twisting, and/or interlooping. Such knitting techniquesmay be utilized to impart various properties to particular regions ofknitted layers with a high degree of specificity and granularity.Various fiber types may be incorporated into different portions of theknitted layers to customize characteristics of layer portions.Additionally, knitted layers may be further processed to physicallymodify selected portions of the knitted layers by, for example,hardening, melting, and/or molding certain fibers of the knitted layers.

FIGS. 4 and 5 illustrate an exemplary display housing 110 including aknitted layer 123 according to various embodiments. At least a portionof display housing 110 may include knitted layer 123 formed by anysuitable knitting technique (see, e.g., knitted layer 120 and knittedlayer 220 illustrated in FIGS. 2 and 3). In some embodiments, displayhousing 110 may be substantially or entirely formed by knitted layer123. While FIGS. 4 and 5 illustrate display housing 110 formed ofknitted layer 123, which includes a continuous and seamless knittedlayer, in some embodiments, display housing 110 may include two or moreconnected and/or separate knitted layers. As shown in FIGS. 4 and 5,display housing 110 may include front-facing portion 112 at a front sideand a facial-interface portion 126 disposed opposite front-facingportion 112. Display housing 110 may also include at least one sideportion extending between front-facing portion 112 and facial-interfaceportion 126. For example, display housing 110 may include an upper sideportion 124A, a lower side portion 124B, a right side portion 124C, anda left side portion 124D. In some embodiments, two or more offront-facing portion 112, upper side portion 124A, lower side portion124B, right side portion 124C, left side portion 124D, and/orfacial-interface portion 126 may be portions of a seamless, integrallyformed three-dimensional knitted layer.

According to at least one embodiment, a viewing opening 128 may bedefined in a portion of display housing 110 disposed away fromfront-facing portion 112. For example, as shown in FIG. 5, viewingopening 128 may be defined by facial-interface portion 126 of displayhousing 110. Viewing opening 128 may extend around at least a portion ofa user's face including the user's eyes such that the user's field ofview is directed within display housing 110 while the user is wearinghead-mounted-display system 100 (see, e.g., FIG. 1). Viewing opening 128may be open to a housing cavity 130 defined within display housing 110.For example, housing cavity 130 may be defined within display housing110 by front-facing portion 112, upper side portion 124A, lower sideportion 124B, right side portion 124C, left side portion 124D, and/orfacial-interface portion 126, as illustrated in FIG. 5. As will bedescribed in greater detail below, housing cavity 130 may be dimensionedto house any suitable components of head-mounted-display device 102,such as image display components and corresponding electroniccomponents. Such components may be securely mounted to suitable portionsof display housing 110.

In some embodiments, one or more additional layers may be disposed on atleast a portion of knitted layer 123 of display housing 110. Forexample, one or more other knitted layers, fabric layers, and/orcoatings may be formed over at least a portion of an interior and/or anexterior surface region of knitted layer 123 of display housing 110,including, for example, at least a portion of front-facing portion 112,upper side portion 124A, lower side portion 124B, right side portion124C, left side portion 124D, and/or facial-interface portion 126. In atleast one embodiment, at least a portion of knitted layer 123 mayinclude a light-blocking material (e.g., a light absorbing material)that prevents or inhibits light from passing through knitted layer 123and entering housing cavity 130 of display housing 110.

Facial-interface portion 126 may form at least part of afacial-interface system that is dimensioned to abut a user's face whilethe user is wearing head-mounted-display system 100. In someembodiments, at least part of facial-interface portion 126 may be formedof a knitted material that is configured to directly abut and/or contactthe user's face. Additionally or alternatively, a separatefacial-interface cushion that is configured to abut and/or contact theuser's face may be mounted to at least a part of facial-interfaceportion 126. For example, a facial-interface cushion including adeformable material, such as a foam material, may be mounted tofacial-interface portion 126.

Facial-interface portion 126 may include various regions that aredimensioned to abut and/or be disposed in close proximity tocorresponding regions of a user's face. For example, as shown in FIG. 5,facial-interface portion 126 may include a forehead region 129Acorresponding to a forehead region of the user's face, temple regions129B corresponding to temple regions of the user's face, cheek regions129C corresponding to cheek regions of the user's face, and a nasalregion 129D corresponding to a nasal region of the user's face. In someembodiments, different regions of facial-interface portion 126 may varyin shape and/or size. For example, a portion of nasal region 129D offacial-interface portion 126 may have a reduced layer thickness and/orwidth in comparison to other portions of facial-interface portion 126.

FIG. 6 shows an exemplary partial cross-sectional side view ofhead-mounted-display device 102, which includes display housing 110. Asshown in this figure, at least one display screen 132 may be disposedwithin housing cavity 130 defined in display housing 110 ofhead-mounted-display device 102. Display screen 132 may include anysuitable type of display screen for displaying content to a user. Forexample, head-mounted-display device 102 may include a single displayscreen 132 disposed within display housing 110 so as to overlap lenses104 such that images produced by a display region of display screen 132are visible to a user through lenses 104. In some embodiments, distinctportions of display screen 132 may be visible to each of the user'seyes, with the screen content visible to each eye being separated by adividing region (e.g., separate eye cups, a central partition, etc.)extending between lenses 104 and display screen 132. Such aconfiguration may enable distinct images to be presented by displayscreen 132 to each of the user's eyes, allowing for three-dimensionalimages to perceived by the user. In some embodiments,head-mounted-display device 102 may include multiple display screens132. For example, head-mounted-display device 102 may include a pair ofdisplay screens 132, with a separate one of the display screens 132being visible to each of the user's left and right eyes.

Display screen 132 may include a plurality of pixels and sub-pixels thatform visible images according to any suitable display technology.Display screen 132 may be any suitable type of display screen, such asan LCD screen (e.g., a backlit LCD screen), an LED screen (e.g., anactive-matrix organic LED (AMOLED) screen), a plasma screen, anelectrophoretic display screen, an electrowetting display screen, acathode ray screen, and/or any other suitable type of image displayscreen. Light may be emitted from a display surface of display screen132 such that displayed images are visible to a user. In some examples,images may be produced by driving sub-pixels of display screen 132 atdifferent currents and/or voltages such that different amounts of lightare emitted from each of the sub-pixels.

According to some embodiments, each lens 104 of head-mounted-displaydevice 102 may be mounted to a corresponding lens fixture 134, which mayextend between lens 104 and a portion of display screen 132. In someembodiments, each lens fixture 134 may surround a viewing path betweenthe corresponding lens 104 and display screen 132. As such, image lightemitted by display screen 132 may be visible to a user through lenses104. According to at least one embodiment, a rear surface of displayscreen 132 may be disposed adjacent to a support member 136. Forexample, as shown in FIG. 6, at least a portion of display screen 132may be disposed between support member 136 and lens fixture 134. In someembodiments, display screen 132 may be disposed within a recessedportion of support member 136 such that display screen 132 is securedwithin support member 136 and/or between support member 136 and lensfixture 134. According to at least one example, support member 136 mayform a chassis that holds and/or supports multiple components ofhead-mounted-display device 102, including display screen 132, lensfixture 134, electronic components 138, and/or various other componentsof head-mounted-display device 102. As will be described in greaterdetail below, support member 136 may be mounted to at least a portion ofdisplay housing 110, thereby securing each of the associated componentswithin display housing 110. Support member 136 may include any suitablematerial, such as a rigid and/or lightweight material, including, forexample, a rigid polymer and/or metal material (e.g., a magnesiumalloy).

In certain embodiments, one or more electronic components, such aselectronic components 138 may be disposed in display housing 110. Forexample, electronic components 138 may be located within housing cavity130 near at least a portion of display screen 132 and/or front-facingportion 112 of display housing 110, as illustrated in FIG. 6. In atleast one embodiment, electronic components 138 may be mounted to aportion of support member 136 between display screen 132 andfront-facing portion 112 of display housing 110. In at least oneexample, electronic components 138 may include, at least in part, aprinted circuit board assembly that is mounted to support member 136and/or to at least a portion of display housing 110.

Electronic components 138 may include, for example, electroniccomponents utilized in the operation of display screen 132 (e.g.,processors, memory, power management devices, communication devices,accelerometers, mapping and/or tracking devices, wiring, etc.).Additionally or alternatively, electronic components 138 may performvarious other functions, such as, for example, functions related tooperations of head-mounted-display system 100. In some embodiments, oneor more electronic components 138 may carry out functions related toaudio subsystems 116 shown in FIG. 1, such as providing audio signals toand/or receiving audio signals from audio subsystems 116. Additionallyor alternatively, one or more electronic components 138 may, forexample, carry out functions related to 1) tracking the position andorientation of head-mounted-display device 102 and/or one or morecontrollers (e.g., hand-held controllers) held and operated by a user,2) performing simultaneous localization and mapping (SLAM) of a user'slocal area, 3) communicating with one or more devices external tohead-mounted-display device 102 (e.g., gaming and/or multimedia consolesor devices, desktops, laptops, tablets, cellular phones, smart phones,wearable devices, embedded systems, internet routers, otherhead-mounted-display devices, hand-held controllers, etc.), 4)monitoring and/or adjusting temperatures within at least a portion ofhead-mounted-display device 102, and/or 5) providing haptic feedback toa user.

FIG. 7 illustrates a portion of display housing 110 according to atleast one embodiment. Knitted layer 123 of display housing 110 mayinclude various regions with different characteristics. For example,knitted layer 123 forming at least a portion of display housing 110 mayinclude two or more regions that have different physical propertiesand/or degrees of one or more physical properties. Examples of physicalproperties that may vary between regions of knitted layer 123 formingdisplay housing 110 may include, for example, rigidity, flexibility,elasticity, deformability, and/or bondability (e.g., bondability to atleast one specified material). Additional examples of one or morephysical properties that may vary between regions of knitted layer 123may include, without limitation, malleability, hardness, density,ductility, plasticity, thermal and/or electrical conductivity, and/orany other suitable measurable and/or observable property. Variouscharacteristics of different regions of knitted layer 123 formingdisplay housing 110 may correspond to particular types of fibers and/orcombinations of fibers present in the different regions. For example,fibers and/or combinations of fibers having desired physical propertiesmay be used to form the various regions of knitted layer 123. In someembodiments, knitted layer 123 may be further subjected to processing tomodify certain physical properties of one or more regions of knittedlayer 123, as will be described in greater detail below.

The exemplary portion of display housing 110 illustrated in FIG. 7 mayinclude a knitted layer 123 that includes at least a first region 140Aand a second region 140B that differ from each other in one or morecharacteristics. In at least one embodiment, first region 140A ofknitted layer 123 may include, for example, at least a portion offront-facing portion 112 and/or at least a portion of upper side portion124A. In some examples, second region 1406, which is separate from firstregion 140A, may include at least a portion of facial-interface portion126. First region 140A may have a first degree of at least one physicalproperty and second region 140B may have a second degree of the at leastone physical property. For example, first region 140A may have a higherrigidity and a lower flexibility than second region 140B. In thisexample, first region 140A may be well-suited for securely mountingand/or supporting components of head-mounted-display device 102 due toits higher rigidity. In contrast, the higher flexibility of secondregion 140B may facilitate fitting and adjustment ofhead-mounted-display device 102 to a user's face by enabling secondregion 140B to readily flex and conform the user's unique facialfeatures.

According to some embodiments, knitted layer 123 forming display housing110 may include a transition region between first region 140A and secondregion 140B having characteristics between those exhibited in firstregion 140A and second region 1408. For example, as shown in FIG. 7,display housing 110 may include a transition region 140C extendingbetween first region 140A and second region 140B. In at least oneexample, transition region 140C may progressively change in degree ofthe at least one physical property proceeding from first region 140Atoward second region 140B. For example, the rigidity of knitted layer123 may decrease and the flexibility of knitted layer 123 may increaseproceeding along transition region 140C in a direction away from firstregion 140A and toward second region 1408. The characteristics ofknitted layer 123 in transition region 140C may vary in any suitablemanner. For example, transition region 140C of knitted layer 123 mayinclude a gradient of one or more physical properties (e.g., a rigiditygradient, a flexibility gradient, a bondability gradient, an elasticitygradient, etc.). Additionally or alternatively, transition region 140Cof knitted layer 123 may include a plurality of sub-regions each havingdifferent degrees of one or more physical properties that incrementallyincrease or decrease in transition region 140C. While FIG. 7 illustratesfirst region 140A, second region 140B, and/or transition region 140Cthat include exemplary portions of knitted layer 123 forming displayhousing 110, first region 140A, second region 140B, and/or transitionregion 140C may additionally or alternatively include any other suitableportions of display housing 110, without limitation. In someembodiments, knitted layer 123 forming display housing 110 may alsoinclude one or more additional regions having any suitablecharacteristics, without limitation. In at least one example, selectedregions of knitted layer 123 having different characteristics, such as,for example, first region 140A and second region 1406, may be disposedadjacent to each other with no transition region between the adjacentregions.

According to at least one embodiment, portions of knitted layer 123 ofdisplay housing 110 may vary in layer thickness. For example, as shownin FIG. 7, at least a portion of front-facing portion 112 in firstregion 140A may have a first layer thickness T1, while at least aportion of facial-interface portion 126 in second region 1406 may have asecond layer thickness T2 that is greater than first layer thickness T1.In some examples, the increased second layer thickness T2 offacial-interface portion 126 may provide additional cushioning andconformability for comfortably abutting and/or contacting a user's face.According to at least one embodiment the thickness of knitted layer 123may be increased by changing the knitting technique and/or pattern usedto form selected portions of knitted layer 123. For example,facial-interface portion 126 may be formed to have the increased secondlayer thickness T2 by knitting a spacer mesh into at least a portion offacial-interface portion 126. In some embodiments, knitted layer 123 mayinclude a thickness transition region in which a thickness of knittedlayer 123 progressively increases or decreases in thickness proceedingbetween a region having a first layer thickness (e.g., thickness T1) anda region having a second layer thickness (e.g., thickness T2).

Characteristics of various regions of knitted layer 123 forming displayhousing 110, such as physical properties of first region 140A, secondregion 1406, transition region 140C, and/or any other regions of knittedlayer 123 of display housing 110, may be obtained by forming the variousregions of knitted layer 123 using one or more specified types of fibers(e.g., filaments), combinations of fibers (e.g., yarns and/or threadsthat each include multiple fibers), and/or other material elements ineach of the respective regions. Any suitable types of fibers,combinations of fibers, and/or other material elements may be utilizedto form knitted layer 123, including, for example, fibers and/or othermaterial elements including any suitable synthetic fiber materialsand/or natural fiber materials. In some embodiments, first region 140Amay include a greater proportion of a first type of fiber than secondregion 140B, and second region 140B may include a greater proportion ofa second type of fiber than first region 140A. For example, first region140A may include a proportion of about 50% or more (e.g., at least about50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%,about 85%, about 90%, about 95%, about 100%) of the first type of fiber.A remainder of first region 140A may include, for example, the secondtype of fiber and/or one or more other types of fibers and/or othermaterials incorporated into knitted layer 123. Second region 140B mayinclude a proportion of about 50% or more (e.g., at least about 50%,about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about85%, about 90%, about 95%, about 100%) of the second type of fiber. Aremainder of second region 140B may include, for example, the first typeof fiber and/or one or more other types of fibers and/or other materialsincorporated into knitted layer 123.

According to various embodiments, transition region 140C may include aproportion of the first type of fiber and/or a proportion of the secondtype of fiber that is between the respective proportions of these typesof fibers in first region 140A and second region 140B. For example, aproportion of the first type of fiber and/or a proportion of the secondtype of fiber in transition region 140C may progressively vary (e.g.,increase and/or decrease) between first region 140A and second region140B. A proportion of the first type of fiber in transition region 140Cmay, for example, incrementally decrease along a gradient proceedingaway from first region 140A and toward second region 140B. Additionallyor alternatively, a proportion of the second type of fiber in transitionregion 140C may incrementally increase along a gradient proceeding awayfrom first region 140A and toward second region 140B. Selectedproportions of various types of fibers and/or other materialsincorporated into different regions of knitted layer 123 of displayhousing 110 may be produced in any suitable manner. For example, coursesof at least one fiber and/or portions of such courses of at least onefiber forming different regions of knitted layer 123 may be patterned inany suitable manner to produce desired proportions of the various typesof fibers (e.g., a region of knitted layer 123 having a 50% proportionof the first type of fiber and a 50% proportion of the second type offiber may include alternating courses of the first type of fiber and thesecond type of fiber).

In some embodiments, various types of fibers, combinations of fibers,and/or other material elements incorporated into knitted layer 123 ofdisplay housing 110 may exhibit desired characteristics, such as desiredphysical properties (e.g., elasticity, flexibility, etc.) as describedabove, at the time the fibers are knitted together to form knitted layer123. Additionally or alternatively, knitted layer 123 may be furtherprocessed following knitting to modify certain types fibers,combinations of fibers, and/or other material elements. For example,knitted layer 123 may be processed to melt and/or harden certain typesof fibers, combinations of fibers, and/or other material elements inknitted layer 123. In at least one embodiment, for example, fibers,combinations of fibers, and/or other material elements includingthermoplastic materials (e.g., fusible fibers, etc.), thermosettingmaterials, and/or curable materials (e.g., photopolymer fibers, etc.)may be incorporated into knitted layer 123. Fibers, combinations offibers, and/or other material elements including such materials may meltinto adjacent fibers and/or other regions of display housing 110 and ormay harden during and/or following processing of at least a portion ofknitted layer 123. Examples of suitable thermoplastic, thermosetting,curable, and/or other types of fibers and/or other materialsincorporated into knitted layer 123 may include, without limitation,polyurethanes, polyether urethanes, polyester urethanes, polyethylenes,ethyl vinyl acetates, polypropylenes, polyesters, and/or silicones.

At least a portion of knitted layer 123 of display housing 110 may beprocessed in any suitable manner. For example, at least a portion ofknitted layer 123 may be subjected to elevated heat and/or pressuresufficient to melt, soften, cure, mold, and/or otherwise modify one ormore physical properties of one or more types of fibers, combinations offibers, and/or other material elements in knitted layer 123. In someexamples, at least a portion of knitted layer 123 may be exposed tolight (e.g., UV light, visible light, etc.) and/or radiation (e.g.,gamma radiation, electron beam (EB) radiation, microwave radiation,etc.) sufficient to effect curing of one or more types of fibers,combinations of fibers, and/or other material elements in knitted layer123. Additionally or alternatively, at least a portion of knitted layer123 may be exposed to one or more chemical agents to effect curing ofone or more types of fibers, combinations of fibers, and/or othermaterial elements in knitted layer 123. According to at least oneembodiment, at least a portion of knitted layer 123 of display housing110 may be molded and/or otherwise deformed during processing to obtaina desired shape. For example, at least a portion of knitted layer 123may be disposed within a mold and/or may be disposed against a suitableforming member such that knitted layer 123 conforms to a desired shapeduring and/or following processing. In some examples, during orfollowing processing, at least a portion of knitted layer 123 of displayhousing 110 may be coated with one or more additional materials (e.g., apolymer material).

FIGS. 8-10 illustrate exemplary techniques for mounting components to atleast a portion of knitted layer 123 of display housing 110. Componentsof head-mounted-display system 100 (e.g., electrical and/or electroniccomponents, structural components, optical components, mechanicalcomponents, etc.) may be mounted to and/or incorporated within at leasta portion of display housing 110 in any suitable manner. In at least oneembodiment, as shown in FIG. 8, an exemplary mounted component 142 maybe bonded to at least a portion of display housing 110. For example,mounted component 142 may be secured to at least a portion of knittedlayer 123 of display housing 110 by a bonding layer 144. Mountedcomponent 142 may be mounted to an internal surface and/or an externalsurface of display housing 110 in such a manner. Bonding layer 144 mayinclude any suitable bonding agent, such as an adhesive material. Insome examples, mounted component 142 may be bonded to multiple portionsof display housing 110. For example, one surface portion of mountedcomponent 142 may be bonded to front-facing portion 112 of displayhousing 110 and another surface portion of mounted component 142 may bebonded to a side portion of display housing 110 (e.g., upper sideportion 124A, lower side portion 124B, right side portion 124C, and/orleft side portion 124D shown in FIGS. 4-7).

In some embodiments, knitted layer 123 of display housing 110 mayfacilitate secure bonding of a component to display housing 110. Forexample, a bonding agent may infiltrate physical features of knittedlayer 123, such as interstices defined between fiber loops and/orsections of knitted layer 123, to further secure the bonding agent toknitted layer 123 of display housing 110. In at least one embodiment,one or more selected fiber types included in at least a portion ofknitted layer 123 of display housing 110 may have increased bondabilitywith respect to one or more bonding agents, facilitating secure bondingof components to knitted layer 123. According to some embodiments, oneor more components of head-mounted-display system 100 may be directlybonded to knitted layer 123. For example, a portion of knitted layer 123and/or a portion of a component may be heated or chemically treated tosoften or melt the portion of knitted layer 123 and/or the component.The portion of knitted layer 123 and/or the component portion may thenbe cooled, forming a bond between knitted layer 123 and the component.

According to some embodiments, one or more components ofhead-mounted-display system 100 may be mechanically secured to at leasta portion of display housing 110. According to at least one example, asshown in FIG. 9, at least one hole 146 may be defined in at least aportion of display housing 110. Hole 146 may, for example, extendthrough a portion of display housing 110 in a thickness direction ofdisplay housing 110. Hole 146 may be defined in display housing 110 anysuitable manner. For example, hole 146 may be formed in display housing110 during knitting of knitted layer 123 of display housing 110. Hole146 may, for example, be formed in knitted layer 123 according to aselected knitting pattern. In some embodiments, hole 146 may be formedin display housing 110 following formation of knitted layer 123 ofdisplay housing 110. For example, hole 146 may be formed by cutting(e.g., die cutting, punching, drilling, machining, etc.) and/or meltinga corresponding portion of knitted layer 123 and/or through any other byany other suitable process. Hole 146 may be defined in any suitableportion of knitted layer 123 of display housing 110, without limitation.In some embodiments, hole 146 may be defined in a rigid or semi-rigidportion of knitted layer 123 (e.g., first region 140A and/or transitionregion 140C shown in FIG. 7), facilitating formation of hole 146 inknitted layer 123 and/or facilitating mounting of one or more componentsto knitted layer 123. In at least one example, a loop and/or any othersuitable attachment feature extending from a surface portion of knittedlayer 123 of display housing 110 may be formed during and/or followingformation of knitted layer 123.

FIG. 10 illustrates an exemplary mounted component 147 that ismechanically secured to at least a portion of display housing 110. Asshown in this figure, mounted component 147 may be disposed adjacent toand/or near hole 146 defined in a portion of knitted layer 123 ofdisplay housing 110 and may be mechanically secured to display housing110 by a fastener 148 extending through hole 146. Hole 146 may be anysuitable type of fastener (e.g., a screw, a bolt, a rivet, a pin, ananchor, a snap, a hook-and-loop fastener, etc.) and/or any othersuitable type of mechanical device and/or member for securing acomponent to display housing 110. Mounted component 147 may be mountedto an internal surface and/or an external surface of display housing 110in such a manner.

FIG. 11 illustrates an exemplary strap subsystem 114 of ahead-mounted-display system 100 according to various embodiments. Strapsubsystem 114 may be partially or entirely formed of a knitted layer 149formed by any suitable technique and/or combination of techniques (see,e.g., knitted layer 120 and/or knitted layer 220 illustrated in FIGS. 2and 3). In some embodiments, strap subsystem 114 may be separate fromdisplay housing 110, as shown in FIGS. 1 and 11. Additionally oralternatively, at least a portion of strap subsystem 114 may beintegrally formed (e.g., integrally knitted) with at least a portion ofdisplay housing 110.

Strap subsystem 114 may be used for adjustably mountinghead-mounted-display device 102 (see, e.g., FIGS. 1 and 6) on a user'shead. As shown in FIG. 11, strap subsystem 114 may include an upperstrap 150, a right side strap 152A (corresponding to a right side of theuser's head), a left side strap 152B (corresponding to a left side ofthe user's head), and a back piece 154. In some embodiments, knittedlayer 149 may form at least a portion of upper strap 150, right sidestrap 152A, left side strap 152B, and/or back piece 154. According to atleast one embodiment, upper strap 150, right side strap 152A, left sidestrap 152B, and/or back piece 154 may be integrally formed by knittedlayer 149. Additionally or alternatively, upper strap 150, right sidestrap 152A, left side strap 152B, and/or back piece 154 may be formed bytwo or more connected and/or separate knitted layers. In someembodiments, back piece 154 may be positioned and dimensioned to restagainst a back portion of the user's head. Upper strap 150, right sidestrap 152A, and left side strap 152B may be coupled tohead-mounted-display device 102 in any suitable manner. For example,upper strap 150, right side strap 152A, and/or left side strap 152B maybe bonded and/or mechanically fastened to head-mounted-display device102. In some embodiments, back piece 154 may include a back-pieceopening 156 that is dimensioned and positioned to securely fit around aback portion (e.g., a portion of the user's occipital lobe) of theuser's head. Back piece 154 and back-piece opening 156 may each have agenerally triangular shape, as shown in FIG. 11, and/or any othersuitable shape.

Knitted layer 149 of strap subsystem 114 may include various regionswith different characteristics to securely and comfortably mounthead-mounted-display system 100 to a user's head and/or to allow forincorporation and/or attachment of various components to strap subsystem114. For example, knitted layer 149 forming at least a portion of strapsubsystem 114 may include two or more regions that have differentphysical properties and/or different degrees of one or more physicalproperties, including, for example, one or more of the physicalproperties discussed above in relation to FIG. 7. Variouscharacteristics of different regions of knitted layer 149 forming strapsubsystem 114 may correspond to particular types of fibers and/orcombinations of fibers present in the different regions. For example,fibers and/or combinations of fibers having desired physical propertiesmay be used to form the various regions of knitted layer 149.Additionally, proportions of fibers and/or combinations of fiber indifferent regions of knitted layer 149 of strap subsystem 114 may, forexample, be selected to provide desired characteristics in each of thevarious regions. In some embodiments, knitted layer 149 may be furthersubjected to processing to modify characteristics, such as physicalproperties, of the different regions as discussed in greater detailabove with respect to FIG. 7.

According to at least one embodiment, knitted layer 149 of strapsubsystem 114 may include various flexible, semi-rigid, and/or rigidsections, enabling strap subsystem 114 to adjustably and securelyconform to various portions of a user's head when the user is wearinghead-mounted-display system 100. In some embodiments, right side strap152A and left side strap 152B may each include at least a portion ofknitted layer 149 having a selected combination flexible, semi-rigid,and/or rigid regions. For example, as illustrated in FIG. 11, right sidestrap 152A and left side strap 152B may respectively include semi-rigidsections 160A and 1606, rigid sections 162A and 162B, and flexiblesections 164A and 164B formed by at least a portion of one or moreknitted layers. Semi-rigid sections 160A and 1606 of right side strap152A and left side strap 152B may, for example, allow for conformity ofright side strap 152A and left side strap 152B around rear and sideportions of a user's head while providing sufficient support to maintainright side strap 152A and left side strap 152B respectively in positionabove the user's left and right ears. Rigid sections 162A and 162B ofright side strap 152A and left side strap 152B may respectively extendbetween right side strap 152A and left side strap 152B andhead-mounted-display device 102 (see, e.g., FIG. 1) to, for example,securely support head-mounted-display device 102 in a desired positionon the user's head. In some examples, rigid sections 162A and 162B mayalso provide support for one or more components of head-mounted-displaysystem 100, such as portions of audio subsystems 116 shown in FIG. 1.

According to some examples, flexible sections 164A and 164B of rightside strap 152A and left side strap 152B may be respectively located atand/or near end portions of right side strap 152A and left side strap152B. Flexible sections 164A and 164B of right side strap 152A and leftside strap 152B may utilized for respectively coupling right side strap152A and left side strap 152B to head-mounted-display device 102 ofhead-mounted-display system 100. Flexible sections 164A and 164B ofright side strap 152A and left side strap 152B may also allow foradjustment of strap subsystem 114 with respect to head-mounted-displaydevice 102 in accordance with a user's particular head shape. In someexamples, at least a portion of flexible sections 164A and 164B of rightside strap 152A and left side strap 152B may have a selected degree ofelasticity to allow for comfortably adjusting head-mounted-displaysystem 100 to fit the user's head. In at least one embodiment, upperstrap 150 may include a flexible and/or semi-rigid portion of knittedlayer 149 of strap subsystem 114, allowing upper strap 150 to readilyconform and/or adjust to an upper portion of a user's head. Upper strap150 may be coupled to head-mounted-display device 102 at, for example, aflexible end section 158 of upper strap 150 and may be adjusted tosecurely fit head-mounted-display system 100 to the user's head. In atleast one example, back piece 154 may include a semi-rigid and/or rigidportion of knitted layer 149 of strap subsystem 114, providing asupportive region abutting a rear portion of the user's head. Knittedlayer 149 of strap subsystem 114 may additionally or alternativelyinclude any other suitable characteristics and/or combinations ofcharacteristics in any suitable portion of strap subsystem 114, withoutlimitation.

According to some embodiments, knitted layer 149 forming at least aportion of strap subsystem 114 may include one or more transitionregions between various portions of strap subsystem 114 (see, e.g.,transition region 140C in FIG. 7). Such transition regions may, forexample, have characteristics between those exhibited in the variousportion of strap subsystem 114. For example, a transition regionextending between a flexible region and a semi-rigid region and/or arigid region may include a gradient that progressively increases inrigidity proceeding from the flexible region toward the semi-rigidregion and/or the rigid region. In at least one example, selectedregions of knitted layer 149 having different characteristics may bedisposed adjacent to each other with no transition region between theadjacent regions. According to some embodiments, portions of knittedlayer 149 of strap subsystem 114 may vary in layer thickness. Forexample, strap subsystem 114 may include relatively thinner regions toprovide greater flexibility and/or to reduce the profile of strapsubsystem 114 in these regions. Additionally or alternatively, strapsubsystem 114 may include relatively thicker regions to, for example,provide additional structural support and/or cushioning.

According to various embodiments, at least a portion of knitted layer149 of strap subsystem 114 may be processed in any suitable manner. Forexample, at least a portion of knitted layer 149 may be subjected toelevated heat and/or pressure sufficient to melt, soften, cure, mold,and/or otherwise modify one or more physical properties of one or moretypes of fibers, combinations of fibers, and/or other material elementsin at least a portion of the knitted layer, as described above inrelation to FIG. 7. In some embodiments, one or more components ofhead-mounted-display system 100 (e.g., electrical and/or electroniccomponents, structural components, optical components, mechanicalcomponents, etc.) may be coupled to at least a portion of strapsubsystem 114 in any suitable manner. For example, various componentsmay be mounted to and/or incorporated within at least a portion of strapsubsystem 114 by bonding and/or mechanically fastening the components toknitted layer 149 of strap subsystem 114 in any suitable manner asdescribed above in relation to FIGS. 8-10. In certain embodiments, oneor more holes, loops, and/or other suitable features may be definedand/or formed in knitted layer 149 of strap subsystem 114 in anysuitable manner (See, e.g., FIG. 9).

FIG. 12 illustrates a portion of a strap subsystem that is coupled to aportion of an exemplary display housing according to some embodiments. Astrap system of a head-mental-display system may be coupled to acorresponding display housing in any suitable manner. For example, oneor more portions of strap subsystem 114 may be coupled to displayhousing 110 of head-mounted-display device 102 by an attachment memberthat is mounted to display housing 110 and/or any other suitable portionof head-mounted-display device 102 (see, e.g., FIG. 1). Additionally oralternatively, one or more portions of strap subsystem 114 may be bondedto, mechanically fastened to, and/or integrally formed with displayhousing 110 and/or any other suitable portion of head-mounted-displaydevice 102.

According to some embodiments, at least a portion of a strap subsystem,such as a portion of exemplary side strap 352 shown in FIG. 12, may becoupled to a suitable feature formed by and/or defined in or on aportion of a knitted layer 323 of an exemplary display housing 310 of ahead-mounted-display system 300. For example, an end section 364 of sidestrap 352 may be coupled to a mounting loop 366 formed by a portion ofdisplay housing 310, such as side portion 324 illustrated in FIG. 12.Mounting loop 366 may be formed by knitted layer 323 of display housing310 in any suitable manner. For example, mounting loop 366 may be formedin knitted layer 323 of display housing 310 according to a selectedknitting pattern during knitting of knitted layer 323. In someembodiments, mounting loop 366 may be produced in knitted layer 323 ofdisplay housing 310 following formation of knitted layer 323 by cutting,melting, and/or molding a portion of the knitted layer and/or by anyother suitable process. In at least one embodiment, at least a portionof end section 364 of side strap 352 may extend through a mounting loop366 to couple side strap 352 to display housing 310. For example, asshown in FIG. 12, end section 364 may pass through mounting loop 366 andmay be mechanically secured (e.g., by hook-and-loop fastening,hook-and-pile fastening, touch fastening, etc.) and/or bonded to anotherportion of side strap 352 in any suitable manner.

FIGS. 13 and 14 illustrate exemplary components that may be incorporatedinto an exemplary knitted layer 423 of a head-mounted-display system400. Knitted layer 423 may form at least a portion of a display housing(e.g., display housing 110 shown in FIGS. 1 and 4-10) or a portion ofstrap subsystem (e.g., strap subsystem 114 shown in FIGS. 1 and 11) asdescribed herein. In some embodiments, at least a portion of one or morecomponents of head-mounted-display system 400 (e.g., electrical and/orelectronic components, structural components, mechanical components,etc.) may be incorporated into at least a portion of knitted layer 423.For example, as shown in FIGS. 13 and 14, wiring 470 for conductingelectrical current, light, and/or other suitable signals between variouselectronic components of head-mounted-display system 400 may be disposedwithin knitted layer 423. Wiring 470 may be, for example, a sheathed orunsheathed conductive wire or cable (e.g., a copper wire, etc.) or anoptical fiber cable. Wiring 470 may be incorporated within knitted layer423 in any suitable manner. For example, wiring 470 may be knitted intoknitted layer 423 during formation of knitted layer 423 such that wiring470 is enveloped by fiber portions of knitted layer 423. According to atleast one embodiment, one or more portions of wiring 470 may protrudefrom any surface portion of knitted layer 423. For example, asillustrated in FIG. 14, a terminal 472 of wiring 470 may protrude from asurface portion of knitted layer 423, allowing for connection of wiring470 to an electronic component of head-mounted-display system 400. Anyother suitable components of head-mounted-display system 400 may beincorporated within at least a portion of knitted layer 423, withoutlimitation.

FIG. 15 is a flow diagram of an exemplary method 1500 for manufacturinga head-mounted-display assembly according to any of the embodimentsdisclosed herein. Steps shown in FIG. 15 may be performed by anindividual and/or by any suitable manual and/or automated apparatus.

As illustrated in FIG. 15, at step 1502, a plurality of fibers may beknit together to form a knitted layer of a head-mounted-displayassembly, the knitted layer extending in three dimensions. For example,a plurality of fibers and/or combinations of fibers may be knit togetherto form a knitted layer 123 of a display housing 110 and/or a knittedlayer 149 of a strap subassembly 114 of a head-mounted-display system100. (See, e.g., FIGS. 1-7 and 11). Knitted layer 123 may extend inthree dimensions and may include, for example, at least a portion offront-facing portion 112, upper side portion 124A, lower side portion124B, right side portion 124C, left side portion 124D, and/orfacial-interface portion 126 of display housing 110. (See, e.g., FIGS.4-7). Additionally or alternatively, knitted layer 149 may extend inthree dimensions and may include, for example, at least a portion ofupper strap 150, right side strap 152A, left side strap 152B, and/orback piece 154 of strap subsystem 114 (see, e.g., FIG. 11).

The knitted layer may include at least two regions, which, whenprocessed, cause (1) a first region to have a first degree of at leastone physical property and (2) a second region to have a second degree ofthe at least one physical property. A transition region may extend fromthe first region to the second region and may progressively change indegree of the at least one physical property proceeding from the firstregion toward the second region. For example, knitted layer 123 of adisplay housing 110 and/or a knitted layer 149 of a strap subassembly114 may include at least two regions, which, when processed, cause (1) afirst region 140A to have a first degree of at least one physicalproperty and (2) a second region 140B to have a second degree of the atleast one physical property, and a transition region 140C may extendfrom the first region to the second region (see, e.g., FIG. 7; see alsoFIG. 11). Transition region 140C may progressively change in degree ofthe at least one physical property proceeding from the first regiontoward the second region.

In some embodiments, during processing, at least a portion of theknitted layer may be exposed to at least one of elevated heat, elevatedpressure, light, radiation, or at least one chemical agent sufficient tomodify the at least one physical property of at least the portion of theknitted layer. Additionally or alternatively, during processing, atleast a portion of the knitted layer may be softened, melted, cured,and/or molded. For example, knitted layer 123 and/or knitted layer 149may be exposed to elevated heat, elevated pressure, light, radiation,and/or at least one chemical agent sufficient to modify the at least onephysical property (e.g., rigidity, flexibility, elasticity,deformability, malleability, hardness, density, ductility, plasticity,thermal and/or electrical conductivity, and/or bondability to at leastone specified material) of at least a portion of knitted layer 123and/or knitted layer 149. In some examples, at least a portion knittedlayer 123 and/or knitted layer 149 may be processed to soften, melt,cure, and/or mold at least a portion of knitted layer 123 and/or knittedlayer 149 (see, e.g., FIGS. 7 and 11).

According to at least one embodiment, the first region of the processedknitted layer may be configured to have at least onehead-mounted-display component mounted thereto. The at least onehead-mounted-display component may be mounted to the first region of theprocessed knitted layer by bonding and/or mechanically fastening the atleast one head-mounted-display component to the first region of theprocessed knitted layer. For example, at least one head-mounted-displaycomponent 142 and/or 147 may be mounted by bonding and/or mechanicalfastening to first region 140A of the processed knitted layer (see,e.g., FIGS. 6-10; see also FIGS. 11-14).

As discussed throughout the instant disclosure, the disclosedapparatuses, assemblies, systems, and methods may includethree-dimensional knitted layers that provide one or more advantagesover traditional display apparatuses, assemblies, systems, and methods.Such knitted layers may allow for head-mounted-display systems to beconstructed with greater customizability and freedom of design.Different portions of a knitted layer may have distinct characteristics,enabling parts of a head-mounted-display system that are conventionallyassembled from multiple pieces to be formed from a single seamlesspiece. The knitted layers may allow for an increased range of physicalproperties to be included in various regions of the head-mounted-displaysystems. For example, a display housing and/or a strap subsystem may beformed from a continuous knitted layer having various rigid sections,semi-rigid sections, flexible sections, and/or elastic sections,eliminating the need for assembling separate pieces having theserespective characteristics. Such continuous knitted layers may havestructurally supportive regions as well as adaptive regions that conformto a user's unique head and facial features, increasing a user's comfortlevel while wearing the head-mounted-display system. The knitted layersmay also reduce the weight of head-mounted-display systems along withreductions in raw material requirements, assembly time, and productioncosts. Additionally, the aesthetic appeal of head-mounted-displaysystems incorporating seamless knitted layers may be improved throughthe elimination of bulky components and/or visible junctions betweenvarious components of the systems.

The process parameters and sequence of the steps described and/orillustrated herein are given by way of example only and can be varied asdesired. For example, while the steps illustrated and/or describedherein may be shown or discussed in a particular order, these steps donot necessarily need to be performed in the order illustrated ordiscussed. The various exemplary methods described and/or illustratedherein may also omit one or more of the steps described or illustratedherein or include additional steps in addition to those disclosed.

The preceding description has been provided to enable others skilled inthe art to best utilize various aspects of the exemplary embodimentsdisclosed herein. This exemplary description is not intended to beexhaustive or to be limited to any precise form disclosed. Manymodifications and variations are possible without departing from thespirit and scope of the instant disclosure. The embodiments disclosedherein should be considered in all respects illustrative and notrestrictive. Reference should be made to the appended claims and theirequivalents in determining the scope of the instant disclosure.

Where a range of values is provided, it is to be understood that eachintervening value between the upper and lower limit of that range, andany other stated or intervening value in that stated range, isencompassed within the scope of the present disclosure. Where the statedrange includes upper or lower limits, ranges excluding either of thoseincluded limits are also included in the present disclosure.

Unless otherwise noted, the terms “connected to,” “coupled to,” and“attached to” (and their derivatives), as used in the specification andclaims, are to be construed as permitting both direct and indirect(i.e., via other elements or components) connection. In addition, theterms “a” or “an,” as used in the specification and claims, are to beconstrued as meaning “at least one of.” Finally, for ease of use, theterms “including” and “having” (and their derivatives), as used in thespecification and claims, are interchangeable with and have the samemeaning as the word “comprising.” It will also be understood that theterm “and/or” as used herein refers to and encompasses any and allpossible combinations of one or more of the associated listed items. Itwill be further understood that the terms “includes,” “including,”“comprises,” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof. The term “exemplary” isused herein in the sense of “serving as an example, instance, orillustration” and not in the sense of “representing the best of itskind.” Furthermore, two or more elements may be coupled together with anadhesive, a clasp, a latch, a hook, a link, a buckle, a bolt, a screw, arivet, a snap, a catch, a lock, and/or any other type of fastening orconnecting mechanism.

What is claimed is:
 1. A head-mounted-display assembly comprising: aknitted layer formed of a plurality of fibers and extending in threedimensions, the knitted layer comprising: a first region having a firstdegree of at least one physical property; a second region having asecond degree of the at least one physical property; and a transitionregion extending between the first region and the second region, whereinthe transition region of the knitted layer progressively changes indegree of the at least one physical property proceeding from the firstregion toward the second region.
 2. The head-mounted-display assembly ofclaim 1, wherein the at least one physical property comprises at leastone of rigidity, elasticity, flexibility, deformability, or bondabilityto at least one specified material.
 3. The head-mounted-display assemblyof claim 1, wherein the plurality of fibers comprises a plurality ofyarns, each of the plurality of yarns comprising multiple fibers.
 4. Thehead-mounted-display assembly of claim 1, wherein the knitted layercomprises at least a portion of a display housing for mounting at leastone head-mounted-display component.
 5. The head-mounted-display assemblyof claim 4, wherein: the knitted layer comprises at least a portion ofat least one of a front-facing portion or a side portion of the displayhousing; and the side portion of the display housing extends from thefront-facing portion toward a viewing opening dimensioned to surround atleast a portion of a user's face.
 6. The head-mounted-display assemblyof claim 4, wherein: the first region of the knitted layer comprises amounting region for mounting the at least one head-mounted-displaycomponent; and the first region of the knitted layer has a higher degreeof rigidity than the second region of the knitted layer.
 7. Thehead-mounted-display assembly of claim 1, wherein the knitted layercomprises at least a portion of a strap subsystem dimensioned to extendaround at least a portion of a user's head.
 8. The head-mounted-displayassembly of claim 1, wherein the plurality of fibers comprises a firsttype of fiber and a second type of fiber that comprises a differentmaterial than the first type of fiber.
 9. The head-mounted-displayassembly of claim 8, wherein at least one of the first type of fiber andthe second type of fiber comprises at least one of a thermoplasticmaterial, a thermosetting material, or a curable material.
 10. Thehead-mounted-display assembly of claim 8, wherein: the first region ofthe knitted layer comprises a first proportion of the first type offiber to the second type of fiber; and the second region of the knittedlayer comprises a second proportion of the first type of fiber to thesecond type of fiber, wherein the second proportion differs from thefirst proportion.
 11. The head-mounted-display assembly of claim 1,wherein the first region has a first average layer thickness and thesecond region has a second average layer thickness that differs from thefirst average layer thickness.
 12. The head-mounted-display assembly ofclaim 1, wherein at least a portion of an electrical circuit is disposedin the knitted layer.
 13. A head-mounted-display system comprising: aknitted layer formed of a plurality of fibers and extending in threedimensions, the knitted layer comprising: a first region having a firstdegree of at least one physical property; and a second region having asecond degree of the at least one physical property; and at least oneelectronic component mounted to the first region of the knitted layer.14. The head-mounted-display system of claim 13, wherein: the at leastone electronic component is mounted to the first region of the knittedlayer by at least one of bonding or mechanical fastening; and the firstregion of the knitted layer has a higher degree of rigidity than thesecond region of the knitted layer.
 15. A method comprising: knittingtogether a plurality of fibers to form a knitted layer of ahead-mounted-display assembly, the knitted layer extending in threedimensions; wherein the knitted layer comprises at least two regionswhich, when processed, cause: a first region to have a first degree ofat least one physical property; and a second region to have a seconddegree of the at least one physical property; wherein a transitionregion extends from the first region to the second region andprogressively changes in degree of the at least one physical propertyproceeding from the first region toward the second region.
 16. Themethod of claim 15, wherein, during processing, at least a portion ofthe knitted layer is exposed to at least one of elevated heat, elevatedpressure, light, radiation, or at least one chemical agent sufficient tomodify the at least one physical property of at least the portion of theknitted layer.
 17. The method of claim 15, wherein, during processing,at least a portion of the knitted layer is at least one of softened,melted, cured, or molded.
 18. The method of claim 15, the first regionof the processed knitted layer is configured to have at least onehead-mounted-display component mounted thereto.
 19. The method of claim18, wherein the at least one head-mounted-display component is mountedto the first region of the processed knitted layer by at least one ofbonding or mechanically fastening the at least one head-mounted-displaycomponent to the first region of the processed knitted layer.
 20. Themethod of claim 15, wherein: the first region of the knitted layercomprises a first proportion of a first type of fiber to a second typeof fiber; and the second region of the knitted layer comprises a secondproportion of the first type of fiber to the second type of fiber,wherein the second proportion differs from the first proportion.